FIELD AND BACKGROUND OF THE INVENTION
[0001] The invention relates to a method and a computer program for determining quantitative
three-dimensional surface topography data from data representing images of a surface
obtained by a microscope.
[0002] Upon observing a sample surface using the appropriate detection conditions, contrasting
variations in tint and/or color in images are caused by the topography of the sample,
also referred to as 'topographic contrast'. However, the extraction of topographical
information from two-dimensional images with such topographic contrast is rather complex.
Zhu et al., Exp. Mech. 51 (2011) 97 describes techniques for obtaining quantitative three-dimensional surface topography
data by scanning electron microscopy (SEM) or from SEM image data. To obtain data
of meaningful accuracy regarding the shape of the scanned surface in a Z-direction
perpendicular to the (mutually perpendicular) X and Y dimensions of that surface,
a calibration of the microscope stage movement for precisely determining movements
of the scanned surface and dimensions of the chamber and of the holder of the sample
of which the surface is scanned, is required. SEM and other microscopes suitable for
calibration are rare and very costly and calibration is time consuming. Moreover,
such calibration may introduce several additional errors in the final results (
Li et al., Opt. Lasers Eng. 50 (2012) 971).
SUMMARY OF THE INVENTION
[0004] It is an object of the present invention to provide a solution that allows obtaining
quantitative three-dimensional surface topography data from two-dimensional images
obtained by a microscope without requiring a priori information about the imaging
equipment and in particular without requiring a calibration of the microscope stage
movement determining movements of the scanned surface and of the dimensions of the
chamber to obtain three-dimensional surface topography data of meaningful accuracy.
According to the invention, this object is achieved by providing a method according
to claim 1.
[0005] This method allows obtaining three-dimensional surface topography data from a series
of at least three images acquired from the same sample surface positioned at different
angles in the microscope. By solving equations of displacements of corresponding points
in two-dimensional image planes between one image and at least two other images, all
acquired from the same sample surface, but acquired from that surface while it is
held at different orientations relative to the optical axis, quantitative three-dimensional
surface topography data can be calculated.
[0006] Corresponding points may for instance be data points each representing a corresponding
pixel or facet (consisting of a cluster of pixels), in particular properties of the
respective pixel or facet and parameters defining the location of the respective pixel
or facet, for instance in terms of the location of the center or of a predefined corner
thereof. For a particularly precise identification of the topographical features,
it is preferred that variations in tint and or color in the image result from the
surface topography of the sample.
[0007] The only physical requirement to obtain the 3D representation is the acquisition
of at least three images of the surface region under study at different tilt angles,
without further need to know details of the tilting parameters. This method can be
applied to sets of images acquired or provided without knowledge of the imaging and/or
rotation conditions. The method according to the invention also allows finding the
precise location and orientation of the sample with respect to the optical system.
In general, this technique may be used to improve other techniques present in the
same measurement systems which are influenced by surface topography (for instance
EDS measurements in SEM systems).
[0008] The invention can also be embodied in a method according to claim 7 that also includes
capturing of the images by microscopy and in a computer program product according
to claim 8 which when executed on a computer, determines quantitative three-dimensional
surface topography data from data representing one image and at least two other images,
all acquired from the same sample surface, but acquired from that surface while it
is held at different orientations relative to the optical axis.
[0009] Particular elaborations and embodiments of the invention are set forth in the dependent
claims.
[0010] Further features, effects and details of the invention appear from the detailed description
and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011]
Figs. 1a)-1c) are schematic illustrations of the influence of the height (level above
a tilted plane) (Δz) of a point P on the observed displacement of that point from a position on an untilted
sample surface when the sample surface is tilted over a tilt angle θ for:
- a) a point in the sample plane (z = 0),
- b) a point above the sample plane (z > 0), and
- c) a point below the sample plane (z < 0);
Fig. 2 is a diagram representing the physical, optical and computational relationship
between situations before and after the movement, in which examples of corresponding
rotation, translation and observations are shown on the right side;
Fig. 3 is an illustration showing nominal orientations of tilting axes in three examples:
Case I: tilt about a sample stage axis only, imaging with x-axis parallel to the tilting
axis,
Case II: tilt about the sample stage axis only, imaging with x-axis rotated over 35°
relative to the tilting axis, and
Case III: tilt about the sample stage axis and about an axis perpendicular thereto,
imaging with x-axis parallel to the sample stage axis;
Fig. 4a) is a map of displacements in y direction (δy) obtained from digital image correlation (DIC) applied to images of Case II captured
before and after tilting over an angle θnom = 4.0°;
Fig. 4b) is a map of the result of fitting of the displacements to eq. 16b (see below)
for calculation of Q4, Q5, and Q6 terms;
Figs. 5a), 5b) and 5c) are graphs showing the fitting of displacements in x and y direction to the values of {Q} (eqs. 16) for the three examples Case I, Case II and
Case III, all the displacement data have been normalized for obtaining zero averages,
each set of data is identified by the nominal angle of tilting;
Figs. 6a) 6b) and 6c) are plots of displacements Δy vs. Δx for the three examples Case I, Case II and Case III (see eq. 18), each set of data
is again identified by the nominal angle of tilt, the alternative (k, l) coordinate system being depicted for each Case;
Figs. 7a), 7b) and 7c) are graphs illustrating methods for finding a unique solution
for the tilting in which the upper graphs illustrate method 1 (py vs. px plots) and the bottom graphs illustrate method 2 (pk vs. θAC);
Fig. 8a), 8b), 8c) are graphs showing the outcome of comparisons between both methods
of solution depicted in Figs. 7a), 7b) and 7c);
Fig. 9a)-9f) are 3D images obtained from Case I (all the scale bars representing 5
µm) in which:
Fig. 9a) is an SEM reference picture,
Fig. 9b) is a reconstruction image obtained using δx data from a set acquired at θnom = 0.5°,
Fig. 9c) is a reconstruction image obtained using δy data from a set acquired at θnom = 0.5°,
Fig. 9d) is a reconstruction image obtained using δy data from a set acquired at θnom = 2.0°,
Fig. 9e) is a reconstruction image obtained using δy data from a set acquired at θnom = 2.0° and with smaller facet size in DIC,
Fig. 9f) is a graph with a set of histograms of reconstructions performed at different
angles and facet sizes;
Figs. 10a)-10d) are 3D reconstructions from Case II, in which:
Fig. 10a) is a reconstruction using δx data from a set acquired at θnom = 2.0°,
Fig. 10b) is a reconstruction using δy data from a set acquired at θnom = 2.0°,
Fig. 10c) is a reconstruction using δk data from a set acquired at θnom = 2.0°,
Fig. 10d) is a graph containing histograms of reconstructions using data from different
axes;
Fig. 11 is a flow chart of an architecture of an example of an algorithm for obtaining
3D maps from SEM images;
Fig. 12 is a flow chart of an example of an algorithm for correction of perspective
deviations;
Fig. 13a) is a SEM image of a sample;
Fig. 13b) is a 3D reconstruction of the sample shown in Fig. 13a); and
Fig. 13c) is a perspective correction applied to obtain the 3D reconstruction of Fig.
13b).
DETAILED DESCRIPTION
[0012] Figs. 1a)-1c) illustrate basic phenomena occurring when tilting a sample on the displacement
(
δ) of the points at different distances from a plane in images acquired from the sample
surface at different angles. The magnitude of the displacement (
δ) of each point between its position in one image and its position in the other image
acquired from the sample surface held at a different angle depends on the value of
the
z coordinates of the points (cf. situations a, b and c in Fig. 1). As a consequence,
from the displacements (
δ) between the positions of corresponding points in the images before and after tilting,
the z coordinates of these points can be determined. Determination of these displacements
of the positions of corresponding points between different images can for instance
be carried out by conventional 2D digital image correlation (DIC) (see e.g.
B. Pan et al., Meas. Sci. Technol. 20 (2009) 062001) between the images before and after the tilting. In the following, it is described
how data describing the three-dimensional profile can be obtained from the DIC data.
Mathematical definitions
[0013] An image can be considered as a matrix of data in which each pixel is characterized
by its position (
x and
y coordinates) and a grayscale intensity. For a rigid body, the modification of coordinates
before and after the tilting (situations labeled A and B, respectively) can be described
as a combination of rotations and translations (see Figure 2). Therefore, a point
i with starting coordinates [
A]=(
xi,A,
yi,A,
zi,A)
real is transformed to final coordinates [
B]=(
xi,B,
yi,B,
zi,B)
real, as:

where [T] is the translation matrix:

and [R] is the rotation matrix:
θ is the angle of rotation around the vector a with components
ax,
ay,
az. This vector is unitary, so:

[0014] Both movements are shown in Fig. 2. Without loss of generality, the
z coordinate of every point
i can be expressed as a combination of a plane with components
px,
py and
pz and the height of every point relative to this plane (
Δzi), as:

[0015] Since we are working in laboratory coordinates,
Δzi vertical shifts are only perpendicular to the plane if
px =
py = 0 (horizontal). This plane can be characterized by a vector located at the origin
normal to the plane with components

[0016] Combining eqs. 1-3 and 5, the following expressions are found:

[0017] Both expressions combine the rotation and the translation of the sample before and
after the movement (situations A and B, respectively).
[0018] The real coordinates of the specimen are to be determined from images taken before
and after the movement (see Fig. 2). Therefore, in addition to the pure physical motion
of the rigid body, there is also influence of the optics in the observed displacements.
This effect is related to the distance between the sample and the optics along the
optical axis, the so-called working distance (
WD)
. As shown in Fig. 2, all points measured out-of-plane away from the center of the
image (
x0, y0) show a difference between the observed coordinates (
xi,
yi), and the real coordinates (
xi,
yi)
real:

[0019] The magnitude of this distortion does not have a substantial influence in the measurements
in SEM, since the working distance is much larger than the values of
Δz. In general, it is confined to the sub-pixel regime and negligibly small. However,
since the present method is based on a comparison of images acquired before and after
tilting the sample by small amounts, the displacements are also in the sub-pixel regime,
so the optical distortion may become relevant, in particular when comparing lower
magnification images (i.e. large image size) before and after tilting. In such cases,
the points close to the border of the image are strongly shifted, which causes important
deviations. This effect can be corrected, as will be described with reference to Fig.
12. However, in the first examples only high magnification images are processed, where
this effect is negligible and no correction for optical distortion is applied. An
example of the application of such a correction for optical distortion will be described
with reference to Figs.13a)-13c).
[0020] Another optical effect that may be considered is a consequence of a translation
tz during the movement of the sample. During the movement, the working distance can
decrease or increase. As a result, the final image may be slightly expanded or contracted,
respectively, by a factor
ε in comparison to the initial image. In typical measurements this factor is close
to 1, and its value can be calculated by evaluation of the change of the observed
coordinates after a displacement in
z direction only:

[0021] In that case eq. 7a can be re-written, with help of eq. 8, as:

[0022] The combination of eq. 9b and eq. 9a leads to:

[0023] Since a factor
ε can be defined as:

we can conclude that, by use of eq. 10 in eq. 11:

[0024] Therefore, the optical effect of the translation
tz during the movement of the sample can be considered to be a uniform effect, while
Δzi << WD and
tz << WD. For instance, at a working distance of 9 mm with an error of 0.1% (i.e. 9
µm), an uncertainty of 30 nm will be obtained in an image of 30×30 microns. If the
image resolution is 1000 x1000 pixels, then the pixel size is 30 nm, which is close
to the uncertainty range. Actually, this value is quite large, since DIC displacements
are calculated at sub pixel regime.
Application of the technique
[0025] In the following, application of the invention is explained with reference to three
examples which illustrate different steps of the method according to the invention.
Although these examples include SEM as image acquisition technique and DIC as displacement
quantification technique, the present invention is not limited to methods including
SEM or DIC, or its combination.
[0026] In the present examples, image acquisition was carried out with a Lyra (Tescan) FEG-SEM
microscope operating at 10 kV and a working distance of 9 mm. The images (30x30 µm
2 and resolution of 768x768 pixels) were recorded in integration mode in order to minimize
the presence of nonrandom noise. The sample was a steel sample with zirconia particles
dispersed on its surface. Fig. 3 shows how the tilting axes were oriented in three
"Cases" forming the present examples. In Cases I and II, the sample was tilted around
a rotation axis of the sample stage only.
[0027] In Case I the images were taken with the
x axis of the image essentially parallel (within experimental constraints) to the tilting
axis. In Case II, the images were scanned in a direction at an angle of about 35°
relative to the tilting axis (see Fig. 3). In Case III the sample was not tilted to
different degrees about the same axis, but first tilted about an axis substantially
in
x direction and subsequently tilted about a second tilting axis substantially perpendicular
to the
x axis. In all cases, images have been captured with the sample tilted to several nominal
tilt angles (
θnom) between 0.5 and 12°). In each case, the images obtained after tilting were compared
by DIC with the initial image before movement. The DIC process was carried out with
Aramis 5.3 software, using facet sizes of 21 and 9 pixels for each (data) point and
overlapping of 11 and 5 pixels, respectively. The DIC process was performed without
activating any additional correction option in the software. The 3D reconstructions
have been plotted with the WSxM software (
I. Horcas et al., Rev. Sci. Instrum. 78 (2007) 013705).
[0028] In the following, first, the method for fitting the experimental data is presented.
Next, the calculation of parameters for the three-dimensional reconstruction and two
methods for finding a unique solution are described.
Fitting of experimental data
[0030] The six terms {
q} represent the rotation, translation and 'optical expansion/contraction' of a flat
plane without roughness (i.e. without
z topography). All the random topographical information is stored in
Δzi. Therefore, we can find the values of {
q} by two fittings of {
xi,B} and {
yi,B} against their corresponding {
xi,A,
yi,A} by using eq. 13. Nevertheless, the experimental data consists of displacements of
the points (facets) in
x and
y directions obtained from the DIC procedure (
δx and
δy, respectively). These parameters can be calculated as:

[0031] Therefore, eq. 13 can be re-formulated in 'DIC terms' instead of 'rigid body motion',
as:

where
Qj =
qj, except that
Q1 =
q1 - 1 and
Q5 =
q5 - 1.
[0032] For each set of DIC data corresponding to a particular tilt, the values of {
Q} are calculated by fitting to eq. 16. Fig. 4a) shows an illustrative example of a
map of DIC displacements in
y direction from Case II and Fig. 4b) shows a fitting performed using eq. 16b. In Fig.
4a), the displacements of the points appear distributed in a diagonal manner, in a
direction perpendicular to the axis of tilt. However, as illustrated in Fig. 4b),
the deviation of the displacement of each point from the displacement of a corresponding
point on the average plane described by the set of Q's depends on
ε, on a rotation term and on
Δzi. The quality of the fittings can be observed in Figs. 5a) to 5c). All plots show
a slope of 1 and ordinate at the origin in zero. Larger ranges of variation of
δx and
δy were obtained when larger tilt angles were used. However, differences can be seen
between plots of
δx and
δy from the same Case. In Case I, the values of
δx are less scattered than the values of
δy of which dispersion increases with the tilt angle (the graphs of
δx and
δy are not of the same scale). Since in Case I, the tilt axis was substantially parallel
to the
x axis, all the topographical information has been transferred to the
y axis only, which explains the difference of behavior. In fact, for
δy, the deviation of each point from the diagonal line is directly correlated to the
value of its z coordinate. In the case of
δx, the deviations are mostly a consequence of noise caused by DIC and image processes.
A different situation can be observed in Case II (cf. Fig. 4b). In this Case, the
increase in dispersion with the tilt angle occurred in both plots. This is a consequence
of tilting about an axis at 35° to the
x-direction (see Fig. 3). Therefore, topographical information is expressed in deviation
of each point from the diagonal line for both
δx and
δy. In Case III, the tilts about mutually perpendicular axes lead to different results.
The tilt about the
x-axis causes most of the dispersion and variation due to differences in
z-coordinate values to be expressed in deviation of each point from the diagonal line
for both
δy, while just noise appears in the direction of the
x axis, as in Case I. The tilt about the
y axis shows the opposite behavior, with most of the dispersion and variation due to
differences in
z-coordinate values to be expressed in deviation of each point from the diagonal line
for both
δx and only noise in the direction of the
y axis.
[0033] The differences between the fittings to data that would have represented displacements
of points on a perfectly plane surface tilted about the same angle and the real data
is of particular interest, since the desired topographical information can be derived
from these differences. After eq. 16, we define:

[0034] The ratio is of interest as well, since:

where
ϕ is the angle formed in the representation of
Δδy versus
Δδx. These plots are depicted in in Fig. 6a)-6c) for all Cases. Fig. 6a)-6c) show the
differences between the corresponding data in Figs. 5a)-5c) and the diagonals (
y=
x). For Case I, the data form an almost vertical line, indicating that the topographical
information is substantially stored in the
y direction only, in agreement with tilting about an axis substantially in the
x direction. In Case II, the data are dispersed substantially along a line deviating
from the vertical, indicating that topographical information is stored not only in
the
y direction, but also in the
x direction. In both Cases, the angle
ϕ is depicted (cf. eq. 18). In Case I,
ϕ= 89,7°, i.e. almost vertical. In Case II,
ϕ = 122,7°, i.e. almost 35° deviated from the vertical, which is in agreement with
the angle between the scanning direction and the tilt axis. In Case III, the differences
found when tilting about the
x axis are dispersed in substantially the
y direction (angle 88,7°) and the differences found when tilting about the
y axis are dispersed in substantially the
x direction (angle - 0,3°). Thus, the sample can be tilted about any angle, the values
of
ϕ angle automatically indicating in which direction or directions the differences representing
the topographical information is to be found (eq. 18).
Calculation of parameters
[0035] For the calculation of the
Δzi data, the {
q} or {
Q} sets obtained previously for evaluating the seven unknown parameters are used:
- four from rotation (ax, ay, az and θ),
- two from the plane (px and py) and
- one from the optical expansion/contraction (ε).
[0036] To reach that objective, we have six equations: (equations 4, 14a, 14b, 14d, 14e
and 18). Therefore, one degree of freedom is left. (Equations 14c and 14d will not
be used, since they include translations
tx and
ty which are also not known.) By combination of the six equations mentioned above, the
following expressions can be found:

[0037] The angle
θ can be obtained from eq. 19 if
az is known, as:

[0038] If
ε equals 1, the three expressions in eq. 19 are not independent and the third equation
does not provide any additional information. However, in any realistic setup this
is not the case, and the value of
ε can be calculated from parameters obtained from fitting after combining eqs. 19:

[0039] At this moment, although one of the seven unknown parameters listed before has been
calculated, there is still one degree of freedom in our system Therefore, a unique
solution cannot be reached from two images alone, and just a 'family of solutions'
in terms of the ratio
ax/
ay can be obtained. In other words, we will get sets of permitted combinations of {
ax,
ay,
az,
θ,
px,
py}. If one of these parameters would be known, the others would be fixed immediately.
The ratio
ax/
ay can be calculated from any pair combinations from eq. 19:

[0040] Two solutions are obtained from each equation, depending on the sign of the square
root, and therefore in total six solutions will be found. However, the correct one
is the only one that is repeated three times, while the other ones are mutually different.
After obtaining
ε and
ax/
ay, there is one last degree of freedom. Values of
az,
px,
py and
θ can for example be calculated from eqs. 4, 14 and 20 after assuming a value for
ax or
ay. The signs of
az and
θ are linked by eq. 20.
Finding a unique solution
[0041] In practice, the sets of points within a 'family of solutions' form corresponding
3D maps with different
z scales. This degree of freedom can be eliminated by including a third SEM image C
and (in addition to the DIC set AB) a DIC set AC representing the displacements of
corresponding points between image A and a third image C. As depicted in Table 1,
three parameters are dependent on the starting situation A only: the plane parameters
px and
py and the sample topography
Δzi (see eq. 5). Therefore, by including another DIC set AC, we introduce only one more
degree of freedom similar to the one in the AB set, but we also introduce three additional
constraints. As a consequence, we can eliminate all unknown parameters from the evaluations
of the DIC sets AB and AC. In fact, a redundancy is obtained that allows two methods
to reach a unique solution.
[0042] Thus, the actual rotation parameters can be calculated from the observed displacements
by requiring that for at least two types of physical parameters of the sample, such
as orientation of the sample plane in the first image and distances of corresponding
points to the sample plane, the value resulting from the first set of displacements
is identical to the value resulting from the second set of displacements. Accordingly,
accurate calibration and control of the rotation is not required, and the need of
complex calibrations has been circumvented. One method (hereinafter Method 1) uses
only the plane parameters (
px,AB =
px,AC and
py,AB =
py,AC) as physical parameters of the sample. In another method 2 (hereinafter Method 2),
the topographical information (
Δzi,AB =
Δzi,AC) is also used as a physical parameter of the sample together with a combination of
the plane parameters.
Method 1
[0043] From corresponding 3D maps with different
z scales, a unique solution for both tilts can be found by determining a solution for
which the values of
px and
py agree for different tilts (i.e. a crossing point of plots of
py vs.
px for different tilts; in other words
px,AB=
px,AC, and
py,AB=
py,AC). Such representations are depicted in the top graphs of Figs 7a)-7c). In each Case,
the graph shows two crossing points, which actually represent the same solution for
positive or negative reconstructions of the 3D topography. It can be seen that in
Cases I and II the lines are quite close to each other and intersect at a very small
angle. This entails a relatively large uncertainty in the determination of the crossing
point. In contrast, the crossing of the lines of each pair is at a much larger angle
in Case III, so that a much more accurate determination of the crossing point is obtained,
assuming that the lines as such are of similar accuracy. This is a consequence of
the number of axes of rotation about which the sample has been tilted. In Cases I
and II, just one axis was used (i.e. identical values of
ϕ in Fig. 6 for different tilts), which leads to information regarding displacement
in directions perpendicular to the single tilt axis only. Rotating the imaging conditions
(i.e. Case II vs. Case I) does not make a big difference in this respect (cf. Case
II in Figure 7), since also in this situation information is derived only from different
amounts of displacement in a single common direction. Nevertheless, since typical
sample holders for SEM apparatus only allow tilting about one axis of rotation, it
is relevant for practice that also from images scanned from a sample in a starting
position and from that sample tilted to different degrees about the same axis, a quantitative
representation of the surface topography of practically meaningful accuracy can obtained.
Method 2
[0044] While method 1 is based on information about the sample plane (
py and
px) only, in method 2 one plane parameter (
pk) and the topographical information (
Δzi) are used (see Table 1). Furthermore, while in method 1, the solution is found by
comparison of independent sets of data from two tilts (AB vs. AC), in method 2 the
information from both tilts is mixed. If two tilts are considered, we will find two
values of
ϕ that can be labeled as
ϕAB and
ϕAC. The average of these angles can be defined as:

[0045] For the further analysis, a new set of coordinates
(k, l, z) replacing (x,
y, z) is defined as:

[0046] These new axes of coordinates are depicted in Fig. 6. The rotation vector can be
expressed in the new set of coordinates with the use of eq. 24, i.e. (
ak,
al, az) instead of (
ax,
ay,
az). In a similar way, we can calculate the components of the plane in this new coordinate
system, as:

[0047] In case of tilts around the same tilt axis or around similar tilt axes (Cases I and
II), this change of coordinate system allows concentrating the topographical information
in the direction of one of the axes, e.g. the
k axis, and minimizing all information other than noise in the direction of the other
axis, e.g. the
l axis, as shown in Figure 6b). Thus, for each tilt we can get one expression equivalent
to eq. 17 in the
k direction by using eq. 24a (and in the
l direction using eq. 24b), as:

[0048] The overall deviations caused by the surface topography in the
z direction can be expressed as the root-mean-square (RMS) deviation in the
k direction, as:

where
N is the number of points evaluated (number of facets), and Δ
δkAB is the average of the
N Δδki,AB values. In this case, the average equals zero, as an ultimate consequence of the
fitting procedure when calculating
{Q}, which subtracts a fitted plane from the original data (cf. eqs. 16 and Fig. 5).
[0049] As illustrated in eq. 18, the topographical information is stored in the ratio of
two rotation terms. In this case, the new coordinate system has been defined in such
a way that most of the topographical information is in the k direction. In this, the
theoretical requirement that
Δzi,AB =
Δzi,AC (see Table 1) is converted into a practical relationship between the RMS of local
deviation data from two different tilts:

[0050] This relationship between
θAB and
θAC is in addition to the relationship
pk,AB =
pk,AC. A practical way to find a unique solution is the representation of a double-plot
of
pk vs.
θAC. To reach it, we calculate
ε and
ay/
ax as before (see eqs. 21 and 22) and find functions
pk(θAB) and
pk(θAC) which depend only on the angle and known parameters. This is done through the subsequent
use of the following equations:
pk (eq. 25a),
px and
py (eq. 14), rotation terms (eq. 3),
az (eq. 19) and
ay (eq. 4).
[0051] Finally, the relation between
θAB and
θAC (eq. 28) is used to define a function
θAB(θAC), and to reach two independent relations that can be labeled as
pk(θAC) and
pk(θAB(θAC)). These functions are shown in the bottom graphs of Figs 7a)-7c).
[0052] By including the determination of the direction in which the largest variation in
differences between the displacements and the fitting of displacements is found in
the fitting of displacements to fitting planes, the accuracy of calculated three-dimensional
surface topography data is improved. More specifically, it can be seen that much less
sharp crossing angles are obtained, particularly for Case II. This procedure is more
accurate because it is based only on one of the parameters of the plane (
pk), which is the one that contains the information when tilting using only one rotation
axis. Nevertheless, we can see that this method can be also used in Case III, where
tilts were performed around two tilting axes oriented in substantially different directions.
This is because, although in this situation not all the topographical information
is expressed in the direction of the
k axis (cf. Figure 6c)), there is still variation caused by topography in the direction
of the
k axis to achieve an accurate solution.
[0053] Both methods 1 and 2 are based on the insight that three connections link the two
tilts from a starting position, as summarized in Table 1. By using the equations in
a way similar to how it was described in the previous paragraph, it is possible to
re-plot each curve in Figs. 7a)-7c) as relations between both tilt angles
θAC and
θAB, as included in Fig. 8. Although this type of plot is illustrative for comparison
purposes, it is inconvenient for computation due to the appearance of many inconsistent
solutions. Four lines appear in each plot. This is because
pk,
px and
py are not independent (cf. eq. 28a). For Case I, the curves from
pk and py are overlapping, since the axis
k is very close to axis
y (cf. Fig. 6a)). In addition, the information from
px is very similar to that obtained from
Δzi (eq. 28). In the other two Cases,
pk is between
px and
py, while data from
Δzi appears different. Nevertheless, in all of the cases, the lines cross basically in
the same point, and similar results are obtained from both methods (cf. Table 2).
Examples of 3D reconstructions of topographical information
[0054] In this section we will show examples of 3D reconstructions performed after the data
treatment explained before. Some 3D mappings of Case I are shown in Figs. 9a)-9f.
The original SEM picture is included in Fig. 9a) as a reference for comparison. Figure
9b shows the reconstruction obtained from the image tilted at
θnom = 0.5° from the initial, using
δx data. It can be seen that this image does not correspond to the actual topography
of the sample, and it is composed only by noise. This can be expected, considering
that the topographical information is only included in the
y axis (cf. Figure 6a)). In contrast, in the pictures 9c)-9e) (based on
δy data) the observed features correspond very well to the image obtained by SEM. The
image taken at
θnom = 0.5° (Figure 9c)) appears noisy when compared with that obtained from
θnom = 2.0° (Figure 9d)), which indicates that 0.5° was a too small tilt to get a good
signal-to-noise ratio for the present sample in view of its roughness. A larger tilt
angle is preferred for samples with a small roughness in order to improve the quality
of the 3D reconstruction as is illustrated by Figs 9d) and 9e) which show the reconstructions
from
θnom = 2.0°. In Fig. 9e) smaller facet sizes were used during DIC than in Fig. 9d). For
this scanned sample, this resulted in a better lateral resolution and a better agreement
with the features appearing in the basic SEM image (Fig. 9a)). The additional detail
shown in Fig. 9e) matches the qualitative information appearing from the basic SEM
image (Fig. 9a)) very well and remains consistent with the more smoothed image of
Fig. 9d). Therefore, use of the lowest facet size that allows DIC recognition is advantageous.
[0055] Figure 9f) shows histograms of the images presented in Figure 9c) to 9e). In addition,
a histogram of an image obtained after
θnom = 4.0° is also included. It can be seen that the histograms are very similar, in
agreement with reconstructions of the same area. The histogram of the image obtained
after
θnom = 2.0° with small facet size appears is wider and lower than the others. This is
because the improved lateral resolution leads to a larger set of
z data, which increase the number of facets for which a
z-value differing from 0 is found.
[0056] Figs. 10a)-10c) show 3D plots of the reconstructions obtained from Case II at
θnom = 2.0°. In this case, different profiles obtained from
x, y and
k axes are shown. As opposite to Figure 9b) and 9c), the same features are identified
from images obtained using
δx, or
δy data (Figs. 10a) and b), since there is topographical information in both. In fact,
this is the reason to define the new pair of working axis
(k, l) to concentrate all the topographical information in one. The result using
k axis is shown in Fig. 10c), which shows a profile matching the profiles shown in
Figs. 10a) and 10b). Thus, consistency between methods 1 and 2 is verified. The histograms
in Figure 10d) shown that also the
z values determined in accordance with methods 1 and 2 are very similar.
[0057] In this particular Case,
ε=1.000036634. With such a small value, it would be tempting to approximate
ε to 1. However, it is preferred not to apply this approximation since then the consistency
between images suffers resulting in alterations of the
z values by factors of 0.7 and 1.7. Therefore, preferably even very small variations
in the working distance are taken into account during processing of image data in
order to obtain accurate 3D images.
[0058] A schematic representation of an example of an algorithm for performing a method
according to the invention for obtaining a 3D reconstruction of quantitative three-dimensional
surface topography data of a sample is shown in Fig. 11. In steps 4 and 5, data representing
three different images 1, 2, 3 (named A, B, C) scanned from the same sample surface
held at different tilts are compared pairwise, resulting in two sets of DIC data 6,
7. In steps 8 and 9 these sets DIC data 6, 7 are each fitted to two fitting planes,
resulting in data sets 10, 11 representing fitting parameters {q}
1-6 and
ϕ as well as the data
δΔx and
δΔy. From the fitting parameters 10, 11, the expansion parameter
ε is calculated in steps 12 and 13 and the ratio
ax/
ay is quantified, leaving one degree of freedom in each set of fitted data 14, 15. In
step 16, by combining the parameters 14, 15 obtained by fitting of the two sets of
DIC data 6, 7 and compensating for expansion and/or contraction, unique solutions
17, 18 for each of the rotations AB and AC are obtained. From the known rotations,
two 3D reconstructions 19, 20 are calculated (one per DIC). In other words, the uncertainty
about the
z scale that remains when considering only one DIC set 6 or 7 is eliminated by adding
a third image, so that the need of complex calibration procedures for determining
the precise amount and axis or axes of rotation is avoided.
[0059] A method to correct the perspective distortions is described with reference to a
flow chart of an example of an algorithm for performing this method, shown in Fig.
12. As indicated with reference to Fig. 2, the measured displacements as for instance
obtained from the DICs result from two effects: the movement of the sample and the
manner of observation of the sample. The perspective distortion can be corrected to
obtain the real coordinates of the sample with the help of eq. 7. The process starts
with the
[x,y,z] data 19 or 20 obtained from the method shown in Fig. 11, which corresponds to an
observation of the sample in an orientation as in situation A (for instance, an average
of both 3D profiles 19, 20 is used). Then, in step 21, eq. 7 is used to calculate
a first iteration of the real coordinates 22 connected to the observed coordinates
in situation A.
[0060] The further steps are for checking the accuracy of the iteration and initiating a
further iteration if the accuracy does not meet a predetermined level. Steps 23, 24
consist of calculation of the real coordinates 25, 26 in the tilted positions B and
C (images 2 and 3 in Fig. 11) corresponding with the first iteration 22, using the
movement parameters 17, 18 (see Fig. 11) obtained before. Next, in steps 27-29, the
perspective distortion for the three different situations is calculated, resulting
in new sets 30-32 of coordinates for the monitored points for the situations A, B
and C. In steps 33, 34, new sets of displacement data 35, 36 are determined from these
coordinates by subtraction. The new sets of displacement data can be regarded as a
'new DIC'. In decision step 37, if this 'new DIC' matches the observed DIC to a sufficient
extent, the calculated set of the real coordinates 22 is accepted as being correct.
If not, the 3D algorithm (i.e. starting with steps 8 and 9) shown in Fig. 11 is employed
on the new
[x,y,δx,δy] values to obtain new sets of
[x,y,z] according to steps 19 and 20. This cycle continues until a predetermined extent of
agreement between the 'new DICs' and the DIC obtained directly from the images has
been achieved.
[0061] An illustration of the effect of the correction for perspective distortions is depicted
in Figs. 13a)-13c) in which Fig. 13a) shows an image with a larger field of view than
the image on which the previous examples of application were based. Its 3D reconstruction
with correction for perspective distortion is shown in Fig. 13b) and the perspective
correction used to reach that reconstruction is depicted in Fig. 13c). The 'U' shape
of the perspective correction in the
y axis is a consequence of the tilting around a rotation axis close to the
x axis. It can be seen that, although the perspective correction is smaller than the
topography of the sample, its magnitude is important in certain situations.
[0062] While, for an easier understanding, the invention is described in the detailed description
with reference to examples of its application, the scope of the invention as defined
by the appending claims is not limited to these examples. As illustrated in Figure
11, the acquisition of a third image at a different tilting angle provides the information
on the basis of which tilting angles and axis can be derived from the images only.
However, the accuracy can be improved by inclusion of more images acquired at other
angles.
[0063] Which angle provides the best results in terms of resolution and accuracy of determined
z-values depends strongly on the roughness of the sample, smaller angles being more
suitable for acquiring surface topology data from rougher samples. While larger angles
allow an improved identification of small roughness, angles should not be too large
in order to avoid problems with facet recognition during the DIC process. For instance,
for the type of sample used in this example, an approximate tilt range would be between
1 and 15 degrees. No previous information about the SEM or other microscopic equipment
is needed, and the 3D map can be just reconstructed from these data by software (DIC
and calculation of rotation parameters) in period of time of typical user operation.
The images can be acquired in various manners, for a useful determination of surface
topography, variations in tint and or color in the images should allow corresponding
points in the images to be identified with a sufficiently fine distribution to recognize
topographical features, such as peaks, ridges and valleys, with a resolution that
is sufficient for the desired level of detail at which the surface topography is to
be determined.
[0064] Several features have been described as part of the same or separate embodiments.
The invention is defined by the appended claims.
Tables:
[0065]
Table 1. Tilt, images, DIC processes, and criteria to find a unique solution.
| Tilting and DIC process |
AB |
AC |
| Images compared |
A and B |
A and C |
| Family of parameters obtained |
{ax, ay, az, θ, px, py}AB |
{ax, ay, az, θ, px, py}AC |
| Connection between both tilts |
same plane |
px = px,AB = px,AC |
| py = py,AB = py,AC |
| same topography |
{Δzi} = {Δzi}AB = {Δzi}AC |
Table 2. Angles obtained from both calculations methods for each Case under study.
| Case |
θAB (deg) |
θAC (deg) |
| Nominal |
Method 1 |
Method 2 |
Nominal |
Method 1 |
Method 2 |
| Case I |
4.0 |
4.832 |
4.754 |
2.0 |
2.443 |
2.341 |
| Case II |
4.0 |
3.973 |
3.900 |
2.0 |
2.037 |
1.973 |
| Case III |
12.0 |
11.724 |
11.997 |
ca. -13.5 |
-13.764 |
-13.281 |
1. Verfahren zur Bestimmung eines Satzes quantitativer dreidimensionaler Oberflächentopografiedaten
aus Bildern, erhalten durch Mikroskopie, umfassend:
das Eingeben von Daten, die mindestens drei Bilder, erhalten durch Mikroskopie von
einer Oberfläche einer Probe, darstellen, in einen Datenprozessor, jedes Bild erfasst
von der Oberfläche mit der Oberfläche positioniert in einer anderen Ausrichtung in
dem Mikroskop in Bezug auf eine optische Achse oder eine zentrale Scanachse des Mikroskops;
das Bestimmen, durch den Datenprozessor, von mindestens einem ersten Satz von Verschiebungen
entsprechender Punkte zwischen einem ersten Bild und einem zweiten Bild und einem
zweiten Satz von Verschiebungen entsprechender Punkte zwischen dem ersten Bild und
einem dritten Bild;
das Anbringen, durch den Datenprozessor, von zwei Richtungskomponenten in zwei Richtungen
von dem ersten Satz von Verschiebungen zu zwei entsprechenden Anbringungsebenen, welche
Anbringungsebenen jeweils von Parametern dieser entsprechenden Anbringungsebene definiert
werden, und das Berechnen anhand der Richtungskomponenten in jeder der zwei Richtungen,
der relativen Verschiebungen der entsprechenden Punkte, welche relativen Verschiebungen
jeweils einen Unterschied der Verschiebung von einem der entsprechenden Punkte und
eine berechnete Verschiebung eines entsprechenden Punkts auf der jeweiligen Anbringungsebene
angibt;
das Anbringen, durch den Datenprozessor, von Richtungskomponenten in zwei Richtungen
des zweiten Satzes von Verschiebungen zu zwei anderen jeweiligen Anbringungsebenen,
welche anderen Anbringungsebenen jeweils von Parametern dieser entsprechenden anderen
Anpassung definiert werden, und Berechnen, anhand der Richtungskomponenten in jeder
der zwei Richtungen, der relativen Verschiebungen der entsprechenden Punkte, welche
relativen Verschiebungen jeweils einen Unterschied zwischen der Verschiebung von einem
der entsprechenden Punkte und einer berechneten Verschiebung von einem entsprechenden
Punkt auf der jeweiligen anderen Anbringungsebene angeben;
das Berechnen, durch den Datenprozessor, einer Ausrichtung einer Probeebene für jedes
Bild und des Winkels und der Drehachse der Probeebene in Bezug auf die optische oder
zentrale Scanachse anhand der Parameter der Anbringungsebenen durch Verlangen, dass
für mindestens zwei Arten physischer Parameter, wie etwa Ausrichtung der Probeebene
in dem ersten Bild und Abstände der entsprechenden Punkte auf der Probeebene, dass
der Wert, resultierend aus dem ersten Satz von Verschiebungen identisch ist mit dem
Wert, resultierend aus dem zweiten Satz von Verschiebungen; und
das Berechnen, durch den Datenprozessor, von mindestens einem Satz quantitativer dreidimensionaler
Oberflächentopografiedaten anhand der berechneten Ausrichtung der Probeebene für jedes
Bild und des Winkels und der Drehachse der Probeebene und mindestens der ersten oder
zweiten relativen Verschiebungen.
2. Verfahren nach Anspruch 1, wobei während der Bilderfassung die Probeebene in einem
Arbeitsabstand von Scan- oder Fokussieroptik ist und wobei die Parameter, welche die
Anbringungsebenen definieren, verwendet werden zum Berechnen von Expansions-/Kontraktionsparametern
welche die allgemeine Bildexpansion oder -kontraktion aufgrund von Änderungen im Arbeitsabstand
zwischen dem Arbeitsabstand während der Erfassung des ersten Bildes und dem Arbeitsabstand
während der Erfassung des zweiten Bildes und zwischen dem Arbeitsabstand während der
Erfassung des ersten Bildes und dem Abstand während der Erfassung des dritten Bildes
darstellen.
3. Verfahren nach Anspruch 1 oder 2, wobei die Anbringung von jedem der Sätze von Verschiebungen
an zwei Anbringungsebenen das Bestimmen der Richtung umfasst, in der die größte Abweichung
in den relativen Verschiebungen gefunden wird.
4. Verfahren nach einem der vorhergehenden Ansprüche, ferner umfassend die Berechnung
von Unterschieden zwischen Standorten und den Verschiebungen, gemessen von zentrischer
Perspektive und Standorten und den Verschiebungen in Laborkoordinaten, anhand der
berechneten Oberflächentopografiedaten, der berechneten Ausrichtung der Probeebene
und der berechneten Drehung der Probe.
5. Verfahren nach Anspruch 4, ferner umfassend ein iteratives Verfahren, das den Unterschied
zwischen den Orten und den Verschiebungen, gemessen von zentrischer Perspektive und
den Orten und den Verschiebungen in Laborkoordinaten, auf der Basis der berechneten
Oberflächentopografiedaten, der berechneten Ausrichtung der Probeebene und der berechneten
Ausrichtung der Probe.
6. Verfahren nach einem der vorhergehenden Ansprüche, wobei das Bestimmen der Sätze von
Verschiebungen durch zweidimensionale digitale Bildkorrelation (DIC, engl. Digital
Image Correlation) durchgeführt wird.
7. Verfahren zur Bestimmung eines Satzes quantitativer dreidimensionaler Oberflächentopografiedaten
von einer Probeoberfläche, umfassend:
das Positionieren einer Probeoberfläche in einem Mikroskop in einer ersten Position
und Erhalten von Daten, die ein erstes Bild dieser Probeoberfläche darstellen;
das Positionieren der Probeoberfläche in dem Mikroskop in einer zweiten Position,
geneigt in Bezug auf die erste Position und Erhalten von Daten, die ein zweites Bild
dieser Probeoberfläche darstellen;
das Positionieren der Probeoberfläche in dem Mikroskop in einer dritten Position,
geneigt in Bezug auf die erste Position, und Erhalten von Daten, die ein drittes Bild
dieser Probeoberfläche darstellen; und
ein Verfahren nach einem der vorhergehenden Ansprüche zur Bestimmung eines Satzes
quantitativer dreidimensionaler Oberflächentopografiedaten aus den Bildern.
8. Computerprogrammprodukt in einer computerausführbaren Form zur Bestimmung eines Satzes
quantitativer dreidimensionaler Oberflächentopografiedaten aus Bildern, erhalten durch
Mikroskopie, umfassend:
Befehle zum Zugreifen auf Daten, die mindestens drei Bilder, erhalten durch Mikroskopie
von einer Oberfläche einer Probe, in einem Datenprozessor, jedes Bild erfasst von
der Oberfläche mit der Oberfläche positioniert in einer anderen Ausrichtung in dem
Mikroskop in Bezug auf eine optische Achse oder eine zentrale Scanachse des Mikroskops;
Befehle zur Bestimmung von mindestens einem ersten Satz von Verschiebungen von entsprechenden
Punkten zwischen einem ersten Bild und einem zweiten Bild und einem zweiten Satz von
Verschiebungen entsprechender Punkte zwischen dem ersten Bild und einem dritten Bild;
Befehle zum Anbringen von Richtungskomponenten in zwei Richtungen des ersten Satzes
von Verschiebungen an zwei jeweiligen Anbringungsebenen, welche Richtungsebenen jeweils
von Parametern dieser jeweiligen Anbringungsebene definiert werden, und Berechnen,
anhand der Richtungskomponenten in jeder der zwei Richtungen, der relativen Verschiebungen
der entsprechenden Punkte, welche relativen Verschiebungen jeweils einen Unterschied
zwischen den Verschiebungen von einem der entsprechenden Punkte und einer berechneten
Verschiebung eines entsprechenden Punktes auf der jeweiligen Anbringungsebene angeben;
Befehle zum Anbringen von Richtungskomponenten in zwei Richtungen des zweiten Satzes
von Verschiebungen an zwei anderen jeweiligen Anbringungsebenen, welche anderen Anbringungsebenen
von Parametern dieser jeweiligen anderen Anbringungsebene definiert werden, und Berechnen,
anhand der Richtungskomponenten in jeder der zwei Richtungen, der relativen Verschiebungen
der entsprechenden Punkte, welche relativen Verschiebungen jeweils einen Unterschied
zwischen der Verschiebung von einem der entsprechenden Punkte und einer berechneten
Verschiebung eines entsprechenden Punktes auf der jeweiligen anderen Anbringungsebene
angeben;
Befehle zur Berechnung einer Ausrichtung einer Probeebene für jedes Bild und des Winkels
und der Drehachse der Probeebene in Bezug auf die optische oder zentrale Scanachse
anhand der Parameter der Anbringungsebenen durch Verlangen, dass für mindestens zwei
Arten physischer Parameter, wie etwa Ausrichtung der Probeebene in dem ersten Bild
und Abstände der entsprechenden Punkte zu der Probeebene, der Wert, resultierend aus
dem ersten Satz von Verschiebungen, identisch ist mit dem Wert, resultierend aus dem
zweiten Satz von Verschiebungen; und
Befehle zur Berechnung von mindestens einem Satz quantitativer dreidimensionaler Oberflächentopografiedaten
anhand der berechneten Ausrichtungen der Probeebene für jedes Bild und des Winkels
und der Drehachse der Probeebene und mindestens der ersten oder zweiten relativen
Verschiebungen.
9. Computerprogrammprodukt nach Anspruch 8, gespeichert auf einem nichtflüchtigen Datenspeichermedium.